Integrated starter for aerial vehicle

ABSTRACT

Systems and methods for starting an engine on an aircraft are provided. One example aspect of the present disclosure is directed to an integrated starter for starting an engine on an aircraft. The integrated starter includes an air turbine starter. The integrated starter includes a starter air valve integrated with the air turbine starter. The integrated starter includes a controller configured to control the starter air valve. The starter air valve can be movable between a first position and at least a second position to regulate the flow of fluid into the air turbine starter. An output torque of the air turbine starter can be dependent at least in part on the flow of fluid into the air turbine starter.

FIELD OF THE INVENTION

The present subject matter relates generally to aerial vehicles.

BACKGROUND OF THE INVENTION

An aerial vehicle can use an air turbine starter to start an engine. Astarter air valve can be used to provide fluid to the air turbinestarter. The air turbine starter can include an air turbine motor, aspeed reducer, and an over-running clutch. The air turbine motorconverts energy from the fluid supplied by the starter air valve to highspeed rotation energy. The speed reducer converts the high speed, lowtorque input to low speed, high torque output usable by the engine. Theover-running clutch allows for the de-coupling of the air turbine motorand speed reducer from the engine during normal engine operation. Thestarter air valve operates independently of the air turbine starter. Insome cases, the starter air valve can provide excessive fluid to the airturbine starter, which can cause unnecessary wear and tear on an engineaccessory gearbox.

BRIEF DESCRIPTION OF THE INVENTION

Aspects and advantages of embodiments of the present disclosure will beset forth in part in the following description, or may be learned fromthe description, or may be learned through practice of the embodiments.

One example aspect of the present disclosure is directed to anintegrated starter for starting an engine on an aircraft. The integratedstarter includes an air turbine starter. The integrated starter includesa starter air valve integrated with the air turbine starter. Theintegrated starter includes a controller configured to control thestarter air valve. The starter air valve can be movable between a firstposition and at least a second position to regulate the flow of fluidinto the air turbine starter. An output torque of the air turbinestarter can be dependent at least in part on the flow of fluid into theair turbine starter.

Other example aspects of the present disclosure are directed to systems,methods, aircrafts, avionics systems, devices, non-transitorycomputer-readable media for starting an engine of an aerial vehicle.Variations and modifications can be made to these example aspects of thepresent disclosure.

These and other features, aspects and advantages of various embodimentswill become better understood with reference to the followingdescription and appended claims. The accompanying drawings, which areincorporated in and constitute a part of this specification, illustrateembodiments of the present disclosure and, together with thedescription, serve to explain the related principles.

BRIEF DESCRIPTION OF THE DRAWINGS

Detailed discussion of embodiments directed to one of ordinary skill inthe art are set forth in the specification, which makes reference to theappended figures, in which:

FIG. 1 depicts an example aerial vehicle according to exampleembodiments of the present disclosure;

FIG. 2 is a schematic cross-sectional view of a gas turbine engine inaccordance with one embodiment of the present disclosure;

FIG. 3 depicts a block diagram of an integrated starter according toexample embodiments of the present disclosure;

FIG. 4 depicts a flow diagram of an example method according to exampleembodiments of the present disclosure;

FIG. 5 depicts a flow diagram of an example method according to exampleembodiments of the present disclosure; and

FIG. 6 depicts a computing system for implementing one or more aspectsaccording to example embodiments of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

Reference now will be made in detail to embodiments, one or moreexamples of which are illustrated in the drawings. Each example isprovided by way of explanation of the embodiments, not limitation of theembodiments. In fact, it will be apparent to those skilled in the artthat various modifications and variations can be made in the presentdisclosure without departing from the scope or spirit of the invention.For instance, features illustrated or described as part of oneembodiment can be used with another embodiment to yield a still furtherembodiment. Thus, it is intended that the present disclosure covers suchmodifications and variations as come within the scope of the appendedclaims and their equivalents.

As used in the specification and the appended claims, the singular forms“a,” “an,” and “the” include plural referents unless the context clearlydictates otherwise. The use of the term “about” in conjunction with anumerical value refers to within 25% of the stated amount.

Example aspects of the present disclosure are directed to methods andsystems associated with an integrated starter for an air turbinevehicle. For instance, the starter air valve and the air turbine startercan be located within a common housing. In addition and/or in thealternative, the starter air valve can be mechanically coupled to theair turbine starter. The integrated starter can start an engine of anaerial vehicle. A starter air valve can provide fluid (e.g., motive air,gases, other fluids, etc.) to the air turbine starter. The air turbinestarter can convert the fluid provided to torque energy usable by theengine.

In some embodiments, the integrated starter can include an integratedcontroller. For instance, the controller can be located within a commonhousing with the starter air valve and/or the air turbine starter. Inaddition and/or in the alternative, the controller can be mechanicallycoupled to the starter air valve and/or the air turbine starter. Thecontroller can be configured to provide control signals to components ofthe integrated starter. In some embodiments, the controller can be anopen-loop controller and does not receive feedback. In some embodiments,the controller can control the opening and closing of the starter airvalve. For instance, as one example, the controller can control the rateof opening of the starter air valve. As another example, the controllercan control the open percentage of the starter air valve. The higherpercentage the controller is open, the more fluid can be provided to theair turbine starter.

Optionally, in some embodiments, the starter air valve can include oneor more valve sensors. The one or more valve sensors can include apressure gauge, a vacuum gauge, a manometer, the like, and/or anycombination of the foregoing. The one or more valve sensors can measurepressure and/or temperature associated with the air turbine starter. Thestarter air valve can modify the rate of opening (or closing) and/or theopen percentage in response to the measured pressure and/or temperature.For example, if the measured pressure and/or temperature indicate thatthe torque output should increase, then the starter air valve can modifythe rate of opening and/or the open percentage to increase the fluidprovided to the air turbine starter.

Optionally, in some embodiments, the air turbine starter can include oneor more starter sensors. For example, the one or more starter sensorscan be included on a stationary portion of the air turbine starter tomonitor a rotating portion of the air turbine starter. The one or morestarter sensors can provide signals indicative of a frequency associatedwith the air turbine starter. The one or more starter sensors canprovide signals indicative of a magnitude associated with the airturbine starter. For instance, in some embodiments, the one or morestarter sensors can include an accelerometer, a microphone, the like,and/or any combination of the foregoing. The one or more starter sensorscan measure mechanical vibration and/or sound. The one or more startersensors can transmit signals indicative of the measured mechanicalvibration and/or sound to one or more computing devices and/or acontroller. The one or more computing devices and/or the controller candetermine an irregular movement of the rotating portion of the airturbine starter based at least in part on the one or more signals. Theone or more computing devices and/or the controller can create anotification to indicate a problem with the integrated starter, engine,and/or accessory gearbox in response to the determined irregularmovement of the rotating portion of the air turbine starter.

FIG. 1 depicts an aerial vehicle 100 according to example embodiments ofthe present disclosure. The aerial vehicle 100 can include one or moreengines 102. In some implementations, at least one of the one or moreengines 102 can be configured as one or more gas turbine engines. Forexample, the one or more engines 102 can include a compressor section, acombustion section, and a turbine section in serial flow order. One ormore of the one or more engines 102 can be configured as a turbofanengine, a turbojet engine, a turboprop engine, a turboshaft engine, etc.In other implementations, one or more of the one or more engines 102 canbe an internal combustion engine, or any other suitable engine for usein an aircraft. The one or more engines 102 can include and/or becoupled to one or more integrated starters 104, as described in moredetail below. The one or more integrated starters 104 can communicatewith a controller 106 via a communication path 108. The controller 106can be, for example, a full authority digital engine control (FADEC).The communication path 108 can be, for example, a communication bus,such as an aircraft communication bus.

The numbers, locations, and/or orientations of the components of exampleaerial vehicle 100 are for purposes of illustration and discussion andare not intended to be limiting. Those of ordinary skill in the art,using the disclosures provided herein, shall understand that thenumbers, locations, and/or orientations of the components of the aerialvehicle 100 can be adjusted without deviating from the scope of thepresent disclosure.

FIG. 2 provides a schematic cross-sectional view of an example gasturbine engine 200 in accordance with the present disclosure. As shownin FIG. 2, the gas turbine engine 200 defines a longitudinal orcenterline axis 202 extending therethrough for reference. The gasturbine engine 200 may generally include a substantially tubular outercasing 204 that defines an annular inlet 206. The outer casing 204 maybe formed from a single casing or multiple casings. The outer casing 204encloses, in serial flow relationship, a gas generator compressor 210, acombustion section 230, a turbine 240, and an exhaust section 250. Thegas generator compressor 210 includes an annular array of inlet guidevanes 212, one or more sequential stages of compressor blades 214, oneor more sequential stages of compressor vanes 216, and a centrifugalcompressor 218. Collectively, the compressor blades 214, the compressorvanes 216, and the centrifugal compressor 218 define a compressed airpath 220. The gas turbine engine 200 can include one or more sensors(not shown) for sensing information related to the gas turbine engine200.

The combustion section 230 includes a combustion chamber 232 and one ormore fuel nozzles 234 extending into the combustion chamber 232. Thefuel nozzles 234 supply fuel to mix with compressed air entering thecombustion chamber 232. Further, the mixture of fuel and compressed aircombust within the combustion chamber 232 to form combustion gases 236.As will be described below in more detail, the combustion gas 236 drivesthe turbine 240.

The turbine 240 includes a gas generator turbine 242 and a power turbine244. The gas generator turbine 242 includes one or more sequentialstages of turbine rotor blades 246, and the power turbine 244 includesone or more sequential stages of turbine rotor blades 248. The gasgenerator turbine 242 drives the gas generator compressor 210 via a gasgenerator shaft 260, and the power turbine 244 drives an output shaft280 via a power turbine shaft 270.

As shown in the embodiment illustrated in FIG. 2, the gas generatorcompressor 210 and the gas generator turbine 242 are coupled to oneanother via the gas generator shaft 260. In operation, the combustiongases 236 drives both the gas generator turbine 242 and the powerturbine 244. As the gas generator turbine 242 rotates around thecenterline axis 202, the gas generator compressor 210 and the gasgenerator shaft 260 both rotate around the centerline axis 202. Further,as the power turbine 244 rotates, the power turbine shaft 270 rotatesand transfers rotational energy to the output shaft 280. As an example,the gas turbine engine 200 may be the first and second gas turbineengines 102 of FIG. 1.

FIG. 3 depicts a block diagram of an integrated starter 300 according toexample embodiments of the present disclosure. The integrated starter300 can be in and/or coupled to the engine 102 of FIG. 1. The integratedstarter 300 can include a starter air valve 302, an air turbine starter304, and a controller 306. The starter air valve 302 can be integratedwith the air turbine starter 304. For instance, the starter air valve302 and the air turbine starter 304 can be located within a commonhousing. As another example, the starter air valve 302 can bemechanically coupled to the air turbine starter 304. The air turbinestarter 304 can include an air turbine motor 308, a speed reducer 310,and an over-running clutch 312.

The starter air valve 302 can be in communication with the controller306. The controller 306 can receive a signal from a full authoritydigital engine control (FADEC). The starter air valve 302 can regulatefluid flow to the air turbine motor 308 based on a signal received fromthe controller 306. The signal received from the controller 306 can bebased on the signal received from the FADEC. The air turbine motor 308can convert energy from the fluid supplied by the starter air valve 302to high speed rotation energy. The speed reducer 310 can convert thehigh speed rotation energy (high speed, low torque) from the air turbinemotor 308 into low speed, high torque used to rotate the over-runningclutch 312. The rotating over-running clutch 312 can be used to engagewith and start the engine 102.

The controller 306 can control the rate of opening of the starter airvalve 302. For example, the controller 306 can cause the starter airvalve 302 to open and shut at a rate of twice per second, or any otherrate. The controller 306 can control the open percentage of the starterair valve 302. For example, the controller 306 can cause the starter airvalve 302 can open to 53%, or any other value between 0% and 100%. Thepercentage open of the starter air valve 302 can be the position of thestarter air valve 302. Changing the rate of opening and/or the openpercentage of the starter air valve 302 can modify the fluid provided tothe air turbine starter 304 from the starter air valve 302. The airturbine starter 304 can convert energy from the fluid provided to theair turbine starter 304 from the starter air valve 302 to a torqueoutput usable for starting the engine 102.

Optionally, the starter air valve 302 can include one or more valvesensors 314. The one or more valve sensors 314 can include a pressuregauge, a vacuum gauge, a manometer, the like, and/or any combination ofthe foregoing. The one or more valve sensors 314 can measure pressureand/or temperature. The pressure and/or temperature can indicate acondition of the starter air valve 302. The starter air valve 302 canmodify the rate of opening and/or the open percentage in response to themeasured pressure and/or temperature. For example, if the measuredpressure and/or temperature indicate that the energy should increase,then the starter air valve 302 can modify the rate of opening and/or theopen percentage to increase the fluid provided to the air turbinestarter 304. As a further example, if the measured pressure and/ortemperature indicate that the energy should increase, then the starterair valve 302 can modify the open percentage of the starter air valve302 from 75% to 80%. As another further example, if the measuredpressure and/or temperature indicate that the energy should increase,then the starter air valve 302 can modify the rate of opening of thestarter air valve 302 from 300 ms open per second to 750 ms open persecond. The numerical examples provided herein are provided for purposesof illustration and discussion and are not intended to be limiting ofthe present disclosure.

Optionally, the air turbine starter 304 can include one or more startersensors 316. For example, the one or more starter sensors 316 can beincluded on a stationary portion of the air turbine starter 304 tomonitor a rotating portion of the air turbine starter 304. In anotherembodiment, the one or more starter sensors 316 can be included on therotating portion of the air turbine starter 304 to monitor the rotatingportion of the air turbine starter 304. The one or more starter sensors316 can include an accelerometer, a microphone, the like, and/or anycombination of the foregoing. The one or more starter sensors 316 canmeasure mechanical vibration and/or sound. The one or more startersensors 316 can transmit the measured mechanical vibration and/or soundto a computing device, such as the computing device 600 of FIG. 6. Thecomputing device 600 can be local to the integrated starter 300. Thecomputing device 600 can be located in the engine 102. The one or morestarter sensors 316 can transmit the measured mechanical vibrationand/or sound to a controller. The controller can be local to theintegrated starter 300. The controller can be located in the engine 102.The computing device 600 and/or the controller can determine anirregular movement of the rotating portion of the air turbine starter304 based on the measured mechanical vibration and/or sound. The one ormore starter sensors 316 can identify anomalies. The identifiedanomalies can originate from the integrated starter 300, engine 102,and/or accessory gearbox. The computing device 600 and/or the controllercan create a notification to indicate a problem with the integratedstarter 300, engine 102, and/or accessory gearbox in response to thedetermined irregular movement of the rotating portion of the air turbinestarter 304.

FIG. 4 depicts a flow diagram of an example method (400) for starting anengine using an integrated starter. The method of FIG. 4 can beimplemented using, for instance, the integrated starter 300 of FIG. 3.FIG. 4 depicts steps performed in a particular order for purposes ofillustration and discussion. Those of ordinary skill in the art, usingthe disclosures provided herein, will understand that various steps ofany of the methods disclosed herein can be adapted, modified,rearranged, or modified in various ways without deviating from the scopeof the present disclosure.

At (402), an opening of a starter air valve integrated with the airturbine starter can be adjusted based at least in part on a signal froma controller. For instance, the integrated starter 300 can adjust anopening of a starter air valve 302 based on a control signal fromcontroller 306.

At (404), fluid can be provided to an air turbine starter can beprovided through the opening of the starter air valve. For instance, theintegrated starter 300 can provide fluid to an air turbine starter 304through the integrated starter air valve 312. In some embodiments, thefluid can be motive air, gases, other fluids, etc.

At (406), the provided fluid can be converted into a torque output. Forinstance, the integrated starter 300 can convert the provided fluid intoa torque output. At (408), the engine can be started using the torqueoutput. For instance, the integrated starter 300 can start the engine102 using the torque output.

Optionally, a signal can be received at a controller or at the starterair valve from one or more valve sensors. The one or more valve sensorscan include at least one of a pressure gauge, a vacuum gauge, and amanometer. At least one of the one or more valve sensors can measurepressure. At least one of the one or more valve sensors can measuretemperature. The opening of the starter air valve can be adjusted basedon the signals from the one or more valve sensors. For example, theintegrated starter 300 can adjust the opening of the starter air valve302 based on the signals from the one or more valve sensors 314.

FIG. 5 depicts a flow diagram of an example method (500) for detectingan anomaly with an air turbine starter. The method of FIG. 5 can beimplemented using, for instance, one or more control systems 600 of FIG.6 and/or the controller 306 of FIG. 3. FIG. 5 depicts steps performed ina particular order for purposes of illustration and discussion. Those ofordinary skill in the art, using the disclosures provided herein, willunderstand that various steps of any of the methods disclosed herein canbe adapted, modified, rearranged, or modified in various ways withoutdeviating from the scope of the present disclosure.

At (502), data indicative of a frequency and/or magnitude associatedwith an integrated air turbine starter can be received from one or moresensors located on a stationary portion of the air turbine starter tomonitor a rotating portion of the air turbine starter. For instance, theone or more control systems 600 can receive data indicative of afrequency and/or magnitude associated with an integrated air turbinestarter can be received from one or more sensors 316 located on astationary portion of the air turbine starter to monitor a rotatingportion of the air turbine starter 304. In another example, thecontroller 306 can receive data indicative of a frequency and/ormagnitude associated with an integrated air turbine starter can bereceived from one or more sensors 316 located on a stationary portion ofthe air turbine starter to monitor a rotating portion of the air turbinestarter 304. In some embodiments, the frequency can be a mechanicalfrequency. In some embodiments, the frequency can be an audio frequency.The one or more sensors can include, for instance, an accelerometer or amicrophone. The controller 306 can be remote from the integratedaircraft turbine starter. The controller 306 can be located in theintegrated aircraft turbine starter.

At (504), an anomaly associated with the integrated air turbine startercan be determined based at least in part on the data indicative of thefrequency and/or magnitude. For instance, the one or more controlsystems 600 can determine an anomaly associated with the integrated airturbine starter 304 based at least in part on the data indicative of thefrequency and/or magnitude. In another example, the controller 306 candetermine an anomaly associated with the integrated air turbine starter304 based at least in part on the data indicative of the frequencyand/or magnitude. The anomaly associated with the integrated air turbinestarter can indicate an anomaly with the engine. The anomaly associatedwith the integrated air turbine starter can indicate an anomaly with theaccessory gearbox.

At (506), a notification indicative of the anomaly associated with theintegrated air turbine starter can be provided. The notification caninclude a visual, optical or other communicated notification. Forinstance, the notification can be communicated to a user interface(e.g., speaker, display, etc.) for alerting a user or technician of theanomaly.

FIG. 6 depicts a block diagram of an example computing system that canbe used to implement the control system 600 or other systems of theaircraft according to example embodiments of the present disclosure. Asshown, the control system 600 can include one or more computingdevice(s) 602. The one or more computing device(s) 602 can include oneor more processor(s) 604 and one or more memory device(s) 606. The oneor more processor(s) 604 can include any suitable processing device,such as a microprocessor, microcontroller, integrated circuit, logicdevice, or other suitable processing device. The one or more memorydevice(s) 606 can include one or more computer-readable media,including, but not limited to, non-transitory computer-readable media,RAM, ROM, hard drives, flash drives, or other memory devices.

The one or more memory device(s) 606 can store information accessible bythe one or more processor(s) 604, including computer-readableinstructions 608 that can be executed by the one or more processor(s)604. The instructions 608 can be any set of instructions that whenexecuted by the one or more processor(s) 604, cause the one or moreprocessor(s) 604 to perform operations. The instructions 608 can besoftware written in any suitable programming language or can beimplemented in hardware. In some embodiments, the instructions 608 canbe executed by the one or more processor(s) 604 to cause the one or moreprocessor(s) 604 to perform operations, such as the operations forintegrating an air turbine starter and starter air valve, as describedwith reference to FIG. 4, the operations for sensing problems with theintegrated starter, as described with reference to FIG. 5, and/or anyother operations or functions of the one or more computing device(s)602.

The memory device(s) 606 can further store data 610 that can be accessedby the processors 604. For example, the data 610 can include data sensedby the one or more valve sensors 314, data sensed by the one or morestarter sensors 316, and/or any other data associated with aerialvehicle 100, as described herein. The data 610 can include one or moretable(s), function(s), algorithm(s), model(s), equation(s), etc. forstarting an engine 102 according to example embodiments of the presentdisclosure.

The one or more computing device(s) 602 can also include a communicationinterface 612 used to communicate, for example, with the othercomponents of system. The communication interface 612 can include anysuitable components for interfacing with one or more network(s),including for example, transmitters, receivers, ports, controllers,antennas, or other suitable components.

Although specific features of various embodiments may be shown in somedrawings and not in others, this is for convenience only. In accordancewith the principles of the present disclosure, any feature of a drawingmay be referenced and/or claimed in combination with any feature of anyother drawing.

This written description uses examples to disclose the invention,including the best mode, and also to enable any person skilled in theart to practice the invention, including making and using any devices orsystems and performing any incorporated methods. The patentable scope ofthe invention is defined by the claims, and may include other examplesthat occur to those skilled in the art. Such other examples are intendedto be within the scope of the claims if they include structural elementsthat do not differ from the literal language of the claims, or if theyinclude equivalent structural elements with insubstantial differencesfrom the literal languages of the claims.

What is claimed is:
 1. An integrated starter for starting an engine onan aircraft comprising: an air turbine starter; a starter air valveintegrated with the air turbine starter; and a controller configured tocontrol the starter air valve, wherein the starter air valve is movablebetween a first position and at least a second position to regulate theflow of fluid into the air turbine starter; wherein an output torque ofthe air turbine starter is dependent at least in part on the flow offluid into the air turbine starter.
 2. The integrated starter of claim1, wherein the starter air valve comprises one or more valve sensors. 3.The integrated starter of claim 2, where the one or more valve sensorscomprise at least one of a pressure gauge, a vacuum gauge, and amanometer.
 4. The integrated starter of claim 2, wherein at least one ofthe one or more valve sensors is configured to measure a pressure. 5.The integrated starter of claim 2, wherein at least one of the one ormore valve sensors is configured to measure a temperature.
 6. Theintegrated starter of claim 2, wherein the starter air valve is furtherconfigured to adjust the opening of the starter air valve from a firstopen percentage to a second open percentage based on signals from theone or more valve sensors.
 7. The integrated starter of claim 6, whereinthe air turbine starter comprises an air turbine motor.
 8. Theintegrated starter of claim 6, wherein the air turbine starter comprisesa speed reducer.
 9. The integrated starter of claim 1, wherein the airturbine starter comprises an over-running clutch.
 10. A method forstarting an engine using an integrated starter, the integrated startercomprising a starter air valve and an air turbine starter, the methodcomprising: adjusting an opening of the starter air valve integratedwith the air turbine starter based at least in part on a signal from acontroller, the controller forming a part of the integrated starter;providing fluid to the air turbine starter through the opening of thestarter air valve; converting the provided fluid with the air turbinestarter into a torque output; and starting the engine using the torqueoutput of the air turbine starter.
 11. The method of claim 10, furthercomprising: receiving a signal from one or more valve sensors.
 12. Themethod of claim 11, where the one or more valve sensors comprise atleast one of a pressure gauge, a vacuum gauge, and a manometer.
 13. Themethod of claim 11, wherein at least one of the one or more valvesensors measures pressure.
 14. The method of claim 11, wherein at leastone of the one or more valve sensors measures temperature.
 15. Themethod of claim 11, further comprising: adjusting the opening of thestarter air valve based on the signals from the one or more valvesensors.
 16. The method of claim 15, wherein the air turbine startercomprises an air turbine motor.
 17. The method of claim 15, wherein theair turbine starter comprises a speed reducer.
 18. An aerial vehiclecomprising: an engine; and an integrated air turbine starter configuredto start the engine; the integrated air turbine starter comprising: anair turbine starter; a starter air valve integrated with the air turbinestarter; and a controller configured to control the starter air valve,wherein the starter air valve is movable between a first position and atleast a second position to regulate the flow of fluid into the airturbine starter; wherein an output torque of the air turbine starter isdependent at least in part on the flow of fluid into the air turbinestarter.
 19. The aerial vehicle of claim 18, wherein the starter airvalve comprises one or more valve sensors.
 20. The aerial vehicle ofclaim 19, wherein the starter air valve is further configured to adjustthe opening of the starter air valve from a first open percentage to asecond open percentage based on signals from the one or more valvesensors